presentation

OJT PROGRAM FOR
MECHANICAL QC INSPECTOR
SAIF HAMED SAIF AL HOSNI GGE221X3/20/2016

Note For clarification..
3/20/2016
 The 11 modules divided into 7 parts due to the
similarity of some disciplines in the activity:
 Quality contain: M1+M5
 Mechanical Pipeline: M2+M3
 Mechanical Piping: M4+M9
 Mechanical Static& Rotating Equipment: M7+M8
 NDT: M6
 Painting & insulation:M10
 Commissioning: M11

Quality: its fitness or suitable for the intended purpose
 It’s the part which deal to
control such a of
contract documents &
drawings The control of
document is with
reference to ISO
9001:2008. which is
mention in the project
contract and the
procedure
 Are documents related
to material and how to
manage them, and its
validating and how it is
stored and where you
store.
3/20/2016
Drawing & document control Material Management

M1/Quality/ Drawing & Document control
3/20/2016
 The control of documents with reference to
ISO 9001:2008 are:
 Contract Quality Plan (CQP).
 SP-1171: specification for quality assurance
for product and service.
 SP-1122: Project quality assurance.
 SP-1131: Specification for handover As-Built
document.
 DEPs: Design and Engineering Practice.

3/20/2016
 Order of precedence of documents:(in Ascending order)
 Code Of Practice (COP): its contain policy approval,
document of measurement, national stuff, financial stuff, etc.
 Guidelines (GUs): the applicable guidelines, ex:
 GU 611: PDO engineering standard and procedures, GU556:
guideline for vendor project document deliverable, GU 459:
guideline for storing & searching information, etc.
 Policy (PL’s): the applicable policy, ex: PL1029: competency
assessment and assurance, PL 1233 contracting &
procurement procedure, PL 1866: quality audit procedure.
 Specifications (SP’s)

 Controlled/Uncontroll
ed copy of document.
 Codes
 Standard
 Drawings/Document
control register.
 Control of obsolete
document.
 Drawings: there are
3 types of drawings:
 AFC Drawings
 Red mark up drawing
 As-Build drawing
 Storage/Retrieval
document
 Project Close Out
3/20/2016

M1/Quality/ Material Management
 Company approved
vendor list.
 Material Certificates.
 TPI Release note
 Special storage
condition of
consumables.
 Safety Data Sheet
 SHOC Card
 Stock/Inventory
Control.
3/20/2016

M5/Quality
3/20/2016
 Is contain 3 main topic:
 Non-Conformance Report (NCR)
 Field Change Control
 Calibration of Measurement Tools.

M5/Quality/NCR
3/20/2016
 NCR: Is violation of against written requirement.
 There are two stage of NCR
 Corrective action
 RFI
 Preservation action
 RE Isometric Drawing
 Photograph of material after modification
 Fit up& welding report (Activity) after modification
 Quality induction training report
 RFI cleared after issue of NCR

M5/Quality/field change controls
 Site Changes Request (SCR): it
raised In case of changes which
affects design were engineering,
requirements of material are
required.
 Work Discussion Memorandum
(WDM):it can be raised due
change of scope, additional
materials requirement, technical
field issues for review record and
action propose.
 Standard Variance
 Calibration: is process to check
and conform that the instrument
used is able to give correct
readings.
 Once the gauge is calibrated, the
details are intended into a work
register of lab, subsequently
calibration certificate is
prepared for record.
 Calibrations are done as per
approved procedure by
competent technicians.
3/20/2016
field change controls Calibration of Equipment

M2/ Mechanical/ CS Pipeline construction &
Production Welding
 Material Handling & control.
 Pipe stacking.
 Surveying & Right of Way pipeline.
 Traceability.
 For example:
 Type of pipe: CS pipe
“Carbon Steel”
 Grade: ISO 3183 L 450
 Pipe Size : Diameter 8in”
“219.1*6.35” thickness
 Length : 11.58 m
 Pipe number :93145
 Stringing.
 Trenching.
 Prepadding
3/20/2016

Production Welding
 Holiday detection
 Peel test
3/20/2016
Pipe Bending
Shrink Sleeve

Production Welding
 Lowering of pipe
 Post padding
 Backfilling
3/20/2016

Production Welding
 Welding: is carry out as approved
AFC WPS which is indicate the
material diameter of the pipe,
position, progression, current type,
electrode and filler wire type, bevel
and groove type, cleaning method
etc.
 The process/ passes of welding in CS
pipeline are:
 Root pass
 Hot pass
 Fill up pass
 Capping pass
For example:
 Type of pipe: CS pipe “Carbon
Steel”
 Grade: ISO 3183 L 450
 Pipe Size : Diameter 8in”
“219.1*6.35” thickness
 Length : 11.58 m
 Pipe number :93145
 Process: SMAW “Shield Metal Arc
Welding”
 Thickness Range: 4.8mm to 9.5mm
 Position of welding : 5G
 Type of electrode: E 6010, E 8010-P1
 Type of current: DC-EN
 Ampere Range: 110-126.5A
 Volts Range: 27.6-31.8V
 Travel speed: 6.11-7.02 mm/sec
 Heat input :0.498-0.572 (KJ/mm)
3/20/2016
Welding

Production Welding
 AFC WPS shall be used for Tie-in
Welds Welder qualification Accordance
with ASME Section IX & SP 1177.
 Electrode storage:
 E 7018-1 H5
 E : Electrode
 70: strength (70000 psi)
 1: Position
1. Flat
2. Horizontal
3. Vertical
4. Overhead
 8: Penetration (A/V)
 1: Impact value (J)
 H5: Hydrogen
 Electrode can be verified by
patch no. and article no.
 Electrodes which are not
hermetically sealed packing or
vacuum requires to be
maintaining from humidity.
 Temperature need to be
monitored.
 Electrode shall be preheated
before it used.
 SDSS red color used for filler
wire.
 DSS yellow color used for filler
wire.
3/20/2016

Production Welding
3/20/2016
Tie-In
welding
 Tie-in welding (SMAW) done after lowering the Pipe
Section in the trench.
 Tie-in welding should be done inside the trench with more
precaution of protection
 Tie-in welding process interruption shall be avoided if any
interruption exists the welding process shall be stopped.
 Tie-in welding for 8” CS pipeline the welding shall be
done in 4 passes Root pass, hot pass, fill pass, capping
pass.
 Alignment shall be done to the pipeline before start the
Tie-in welding.
 The alignment of the pipeline shall be supported by side
boom/ Crain.
 Clamper removal it’s a tool that hold the end side of
pipelines in case of welding alignment purpose and to
give the required root gap as per AFC WPS.

Production Welding
3/20/2016
Tie-In
welding
 Weld cleaning. Weld cleaning by, wire
brush, power brush, grinding wheel &
file.
 The after complete weld shall be
inspected visually before it offered to
NDT inspection.
 The Method used in NDT to inspect
the CS Pipeline to the complete weld
is MPT “Magnetic Particle Testing”.
Then it Evaluate for Acceptance
criteria.

Production Welding
3/20/2016
Hydrostatic
test
 Hydrostatic test. To detect the Weld
integrity and pipeline yield strength
 Hydrostatic test: Should be 1.5 times
of Operating Pressure.
 Dewatering - this involves pushing
pigs through the pipeline propelled by
a gas to remove the water prior to
start-up.
 Drying &preservation: Dew Point it’s
a measurement of moisture inside the
pipe or pipeline for the end of the
drying process

M3/ Mechanical/ GRE Pipeline construction off
plot
 GRE: Glass Reinforced Epoxy
 Control document is SP-1208: Pipeline
construction specification for CS and
GRE pipeline and procedure handling
and storage.
 For SNCP Project GRE Pipes comes in
different pressure such as
 PN112: indicate pressure of 112 bars.
 PN50: indicate pressure of 50 Bars.
 PN16: indicate pressure of 16 Bars.
 Each type having different color, size,
diameter, and function.
 Material receipt: It’s a document shows
the details of materials such as: MRR
Number, Order Number, Heat number,
Supplier, Size, and Statue Location.
 Storage & handling: transportation,
handling and storage of pipes fitting and
adhesives.
3/20/2016

M3/ Mechanical/ GRE Pipeline construction off
plot
 Storage of adhesive kits:
the adhesive kit should be
store cool and isolated
from the temperature as
per the standard.
 Self life should be kept in
mind for all consumables.
The Self life of adhesive kit
is having 9 month
 Pot life: it’s the expected
life of the mixture or things
to be used
3/20/2016

M3/ Mechanical/ GRE Pipeline
construction off plot
 There are 3 types of
GRE Joints:
 1. Threaded Joint
 Hi pro plus
 L.C Area
 2.Lamination Joint
 Epoxy kits
 3. Flanged joint
3/20/2016

M3/ Mechanical/ GRE Pipeline
construction off plot
 Field thread fabrication: pipe
preparation, tapering, cleaning, mold
preparation, epoxy thread paste
preparation, threading, curing, mold
removal and thread inspection.
 Wadi crossing: there are four type
Wadi:
 Flood plains
 Wadi type A
 Wadi type B
 Wadi type C
 Road crossing
3/20/2016

M4/ Mechanical/Piping construction &
Production Welding (on plot)
 Handling & storage of DSS, SS
material:
 Nylon slings shall be used for lifting
and handling of DSS & SS material.
 Welding inspection :
 Before (Prior)
 During
 After
 Inspection of weld repairs & acceptance
checks
 Pre-test line check & punch list:
checking all construction activities
completed including support and
attachment welding under the piping
and all NDT are completed and all
necessary report are available-list out
all record non compliance during line
check
 CCMS: completion certificate
mechanical system. It has two type :
 Design stage
 Construction stage
 Once system complete, it will clearance
another system. Like mechanical
construction check sheet completed.
Then pre-commissioning system start to
gives unique number to any system.
 QC release of test-Package for hydro
test: This sheet which must be done
before hydro test its shows all complete
document (welding report, NDE report,
PWHT and NCR closeout).
3/20/2016

 Hydro test preparation: [PIPING]
 Approved hydro test procedure & ITP, mark
& identify test limits, check all ‘A’ punch
list items completed, line walk completed,
record ‘B’ punch items, witness line
flushing, check pressure gauges calibration,
testing manifold is approved, check vents
& drains points, check water certificate
chloride content not exceed 200ppm, check
chart pressure recorder, check relief valve
calibration, before starting of test – line test
pack is released for testing
 Check test pack is prepared as per approved
formats, & as per approved index, all
relevant check sheets signed, record valves
details, check for line list, mark up PEFS,
check for punch list items recorded.
 Weld history sheet is updated with all joints
covered along with suitable NDT &
acceptance.
 Correct PEFS or P & ID and
isometric drawings.
 Check visually damage. During
hydro test check for any leaks check
for pressure drops if any, check
chart recorder
 [This is separate subject related to
mechanical motor alignment] -
write method statement details, ITP
details, DEP & SP details.
 Provide Separate heading required
& date required
 Test witnessing & acceptance :
check all gauge calibration done or
not and chart record , always check
PRV pressure relive value calibration
and check at latest 3 times.
3/20/2016

3/20/2016
 Piping re-instatement: this the last step for piping that insulate all pipes, flange, gasket, alignment,
support and slop if required. As per the latest REV, correct stud bolts to be installed and torque to be
done as per SP 2020, and fittings also to be installed such as gauges, flange, vessel, pressure vessel,
etc.
 Flange management: as per SP 2020
 Flange must always visually inspect of the surface finish. & rating
 Ensure the correct size bolts and nuts material is used. As per drawing.
 Check the type, class, size and material specification of the gasket before using and ensure the gasket fits
correctly.
 Always use a new insulation kit freshly removed from manufacturer package and follow the instruction.
Check torque values as per vendor recommendations
 Follow required torque values procedure. Approved by company
 Tie-in welding (shutdown): its when existing line is connected with new line (by needs of break up
flange fitting or pipe seems spools, certain spools can be hydrotest. this one type of new connection
making point on alive pipe which have isolation valve shutdown will be done the pipe will cut by cold
cutting machine from tow proposed marked area then they will make bevel surface preparation welding
will be done to installed breakup flange connection required NDT & inspection shall be done and they
fabricated & tested spool will be installed final inspection & box up will be done with required torque
values. And test pack shall be prepared for quality documentation.
 Golden joint: when new break up connection is help of flange fitting where hydrotest cannot be done
only NDT is applicable.

3/20/2016
 Hot Tap: Welding on pressurized pipes (live lines): If there is a pipe (live) which have
no valve they will fabric a pipe which have value and cut half of fabric pipe and weld
it in the pipe (live) and they make cold drilling. Guideline of hot tapping in general:
 Confirm that the installation site meets the minimum upstream and downstream pipe
diameter requirements.
 Weld a two inch mounting adapter on the pipe. Make sure the mounting adapter is
within ± 5° perpendicular to the pipe centerline (see previous page). The pipe
opening must be at least 1.875 inches in diameter.
 Connect a two inch process connection on the mounting adapter.
 Connect an isolation valve on the process connection. The valve's full open bore
must be at least 1.875 inches in diameter.
 Hot tap the pipe.
 Close the isolation valve. Run a static pressure check on the welds. If Pressure loss
or leaks are detected, repair the joint and re-test.
 Connect the flow meter to the isolation valve.
 Calculate the sensor probe insertion depth as described on the following pages.
Insert the sensor probe assembly into the pipe

M9/ Mechanical/ GRE U/G piping (on plot)
 Storage of adhesive kits
 Trench preparation
 Special tools: tools that especially
used in different process of GRE
pipe such as:
 M86, M86XL shaver.
 C/W arbors.
 Pipe shavers
 Flapper sander
 Hack saw
 Saber saw
 Abrasive wheel
 Pipe cutting
 Edge preparation
 Trial assembly
 Surface preparation
 Adhesive band kit 3/20/2016

M9/ Mechanical/ GRE U/G piping (on plot)
 Hydro test preparation: hydro test
package it’s to collect all the details which
is required for starting hydro test example:
 Daily report
 Method of statement
 Heat number.
 Gauge report: gauge calibration by third
party.
 Test manifold
 Hose pipe (Tested one)
 Water test report
 Hydro test procedure (Approved)
 ITP/ QCP (Latest Revision)
 Air compressor
 Dead weight center: Recheck the gauge
calibration.
 P& ID diagram
 Test limit
 Hydro test:
 Dewatering
 Drying
 Reinstatement
 CCMS
3/20/2016

M7/ Mechanical/mechanical static equipment:
stabilizer column, pressure vessel, re-boilers,
HTF heaters, Air fin cooler, AP/HP flare
3/20/2016
 DEP 61.10.08.11: field inspection prior to commissioning of mechanical equipment. The
Information in this DEP has been arranged type of equipment such as: columns, furniture,
bumps, etc.
 MS: MMS-016 for erection installation & Alignment of static equipment.
 SP for pressure vessel plate, carbon steel for moderate and lower Temp. Service.
 QCP: quality control plane, it’s a document provided by the contractor in the a process of
checking the equipment in sequence of activity and inspection (Receive of material, Pre-
installation, during installation) it contain : activity, type of test, controlling document,
acceptance criteria, frequency of inspection, Responsible person in location, verification
document, inspection stages.
 Lifting plane: it’s a document generated by contractor for installation and lifting of
equipment.
 Bill of materials (BOM): its document table specified list of materials used such as plate,
pipe, flange, elbow, dish, pad, nuts, poles, rings, lifting lugs, and list of internal materials.
 Vendor manual: it’s a document provided by the manufacturer where it states operation
sequence, controlling, treble shooting, rectification, maintenance sequence.

stabilizer column, pressure vessel, re-boilers,
HTF heaters, Air fin cooler, AP/HP flare
3/20/2016
 Installation of static equipment: when the equipment arrive
at the site based on the weight mention in GA drawings and
data sheet lifting plane is generated by contractor and
submitted to client for review and approval and this process
type of rigger lifting supervisors, Approval required, verifying
location of installation, positioning, clearance and weather
condition are important factors of any installation of static
equipment.
 Foundation release
 Erection of Equipment
 Alignment & leveling
 Installation of access ladder & plate form
 Clearance for grouting

stabilizer column, pressure vessel, re-boilers, HTF
heaters, Air fin cooler, AP/HP flare
 Stabilizer column
 Re-boiler
 HTF heater
 AP/HP flare
 Air fin cooler/fin fan cooler
 Pressure Vessel
 Vessel internal installation: it’s a
part of vessel internal structure used
for separation and filtration of vapor
and liquid, internals such as:
 Demister pad with 100 mm
thickness.
 Wire mesh used for vapor
filtration.
 Scopentoeter: is SS plate
material used for crude inlet
deflection.
 Collection dray: its used as
collection and distribution of liquid
through internal pipe connection
of bottom of the vessel.
 Vortex breaker: its deflected
plate material installed at the
bottom of nozzle outlet
connection, its helps the liquid to
restricted flow.
3/20/2016

stabilizer column, pressure vessel, re-boilers, HTF
heaters, Air fin cooler, AP/HP flare
3/20/2016
 Presser vessel: its an equipment used in process plant purpose of separation, there
are two type of vessels orientation:
 Vertical
 Horizontal
 Also there process is of two types:
 Two stage vessel its for liquid and vapor
 Three stage vessel its for liquid and vapor and hydrocarbon.
 Vessels either can be:
 Above the ground vessel which usually used for process.
 Below the ground vessel which for drain & hydrocarbon collection.
 Attachment (internal and external parts)
 External: demister, scheopentoeter, vortex breaker, collection dray, wire
mesh, internal rungs & lugs, swivel deck, etc.
 External: nozzles, plate form, hinges, manway, relief valve, lifting lug, gas
outlet, liquid outlet, etc.
 Fabrication of vessel:

M8/ Mechanical/ Mechanical Rotating equipments:
Flash Gas Compressors, Process Pumps
 Rotating equipment: it’s
basically contain rotating part
and add kinetic energy to the
process. Such as: Motors,
Pumps, Compressor.
 Installation of Rotating
equipment
 Foundation release
 Erection of Equipment
 Preliminary alignment: it’s a
process which is been carryout
for the pump skid initial
installation on concrete
foundation anchor bolts once
arrested after securing motor and
pump and leg base. Alignment
will be adjusted based on shims
as supplies by vendor, initial
readings will be recorded.
Further Distance between Shaft
Ends “DBSE” will be noted and
skid will be release for grouting.
 Check for elevation
 Level
 Position
 Orientation
3/20/2016

 Axial & Radial alignments: Normally we
are using rim and face methods. There are
two types (1) Two dial indicator method
and (2) Three dial indicator method. In two
dial indicator method put one dial indicator
in the radial portion of motor shaft and
other in the axial portion (face portion) of
the motor shaft. Set the dial in zero at zero
degree. Then rotate the shaft at 0, 90, 180
and 270 degrees. The readings in each
turn must be within plus or minus 0.05mm.
In three dial indicator method fix one in the
radial and two in axial. Then rotate the
shaft at 0, 90, 180 and 270 degrees. The
radial reading in each turn must be within
plus or minus 0.05mm.The axial reading
can be determined by taking the average
of two dial indicators. The other methods
are rotalign, laser alignment and reverse
dial indicator method. In reverse dial
indicator method in which two dial
indicators will be fixed in the radial of
motor. The other steps and tolerances are
same.
 Gap for grouting are Ok
 Check for Equipment Preservation
 Topping up preservation oil
 Alignment of Driver and Driven unit
with piping Connected
 Alignment of Driver & Driven unit
without piping connected
 Final Inspection & Compilation of QC
Dossier including CCMS Check Sheets:
 Motors: A machine especially one
powered by electricity or internal
combustion (combustible), that supplies
motive power for a vehicle or some other
device with motion power. It’s produced or
imparts motion. Or (it’s a device that
converts any form of energy into
mechanical energy).
3/20/2016

 Pumps: it’s a device that moves fluid (liquids,
and gases) or sometimes, slurries, by
mechanical action. Usually in SNCP two types
of pumps are used which are: centrifugally
pumps, and reciprocating pumps. Which are
used for transferring liquids (condensate&
water).
 Major classifications of pumps are:
dynamic pumps and positive
displacement pumps. Centrifugally type
is dynamic, where as reciprocating pumps
are positive displacement pumps.
 Centrifugally pumps: it’s a sub-class of
dynamic types of pumps its used to
transport fluid by the conversion of
rotating kinetic energy to the dynamic
energy of the fluid flow. The rotational
energy typically comes from engine or
electric motor.( giving the same volume
and pressure flowing)
 Reciprocating pumps: it’s a class of
positive displacement pumps which
includes the piston pump, plunger pump,
and diaphragm pump. It’s often used
where a relatively small quantity of liquid
is to be handled and where a delivery
pressure is quite large. (its to take liquids
with low pressure and pump it with more
pressure).
 Compressor: is a mechanical device
that increases the pressure of the
gas by reducing it volume.
 An air compressor is a specific
type of gas compressor.
 Compressors are similar to
pumps both increases the
pressure on fluid and both can
transport the fluid through a pipe.
3/20/2016

M6/ Mechanical/ Non Destructive Testing
 Type of NDT methods:
 Visual testing (VT)
 Direct: Visual
Inspection by Direct
 Remote: Inspection
thru records
example binocular,
videos, Boroscope.
3/20/2016

 Radiography testing: it was
discovered by Wilhelm Rontgen.
 There are three type of radiography
uses:
 Medical
 Industrial
 Agree cultural
 There are two type of radiography: X-
Ray & Gamma Ray
 X-ray: There is two types of X Ray
Machines.1 Stationary 2 Portable type,
High Energy X-Ray Machines: eg.
LINAC, (Linear Accelerator) & Van De
Craft generator
 Gamma ray: 1.Stationary 2. Portable
Type. Ex: Iridium 192, Cesium130,
Yetterbium 169 Cobalt 60, Selenium 75.
& Thulium 170
 X-ray Operating by battery current or
current, Gamma ray producing by
isotope.
 Exposure time Calculated by
Distance, Strength of Isotope or
X-Ray, Film Types and material
thickness.
 The Measurement unit of
radiation is Curie Or Becquerel
 The unit of measuring expose is
mR or Sievert
3/20/2016

 Films: there are three types of films:
 Monochromatic Medical X-Ray Films
 Dichromatic : Industrial use”
 Panchromatic “ Photography &
cinematography use”
 Types Of Films
 Class 1: slow film, fine grain structure.
 Class 2: medium grain structure.
 Class 3: fast film, coarse grain
structure.
 Films made from polyester base with silver
bromide or silver halide; they Protecting
Layers by gelatin.
 Film processing:
 There are three stage of developing:
 Developing: Alkaline Solution ( Hydro quinine,
metol,)
 Stop bath: Water & 5% Glacial Acetic Acid.
 Fixing & cleaning: Sodium Thio Sulfate
 Cleaning
 Film drying
 Film Density:
 Based upon darkness.
 The density require for X-ray is 1.8-3.5.
 The density require for Gamma ray is 2-3.5.
 Density measured by densitometer or
density strip.
 The Illumination for viewing the film we need
30-300 foot candles Light equalant.
 Film Sensitivity:
 S= least wire thickness / job thickness
x100
 IQI: image quality indicator.
 Type of IQI:
3/20/2016

3/20/2016
 MPT: Magnetic Particle Testing using only in ferrous materials, the principle of MPT
is magnetic field or magnetism
 The types of magnet:
 Diamagnetic.
 Paramagnetic
 Electromagnetic: AC, DC, Half way AC & Half Way DC.
 AC Yoke lifting power is 4.5 Kg
 DC Yoke lifting power is 18 Kg or 40 LPS.
 DC magnet / prod type: using by dry particle method, and AC used for wet
particle method.
 Types of Testing by Half Way AC & DC Method
 Head Shot Methods
 Coil Shot method.
 Central conductor method
 MPT not applicable for SS materials.
 Pie indicator checks the existing of flux line.
 Burma Castrol strip: checking the sensitivity of the Flaw
 Gauss Testing for the Flux leakage
 Demagnetization:

3/20/2016
 Liquid Penatrant Testing
 The Principal of Liquid penatrant test by Capillary Action
 LPT just applicable for non-porous materials.
 To deduct only surface defects.
 Type of LPT:
 Aqueous
 Non- Aqueous
 Fluorescent
 Penetrate, cleaner, developer are used in the procedure of LPT.
 Types of penetrate :
 Water washable: it washed by water.
 Solvent based: it cleaned by solvent.
 Emulsifier usually used to control non-relevant. indications
 Method A: Water-Washable
 Method B: Post-Emulsifiable, Lipophilic
 Method C: Solvent Removable
 Method D: Post-Emulsifiable, Hydrophilic
 Developer should be free from Chlorine contain.
 Defect: the discontinuity exceeding the Acceptable Limit so it will be rejected.
 Discontinuity: is a Smallest Flaw.

 UT: ultrasonic testing, its using ultrasound
waves which is having frequency sound waves
to detect volumetric defects “internal or
subsurface defects”.
 The sound waves measured by Decibel dB
 Particle Movement is from its rest position.
 Types of waves:
 Longitudinal waves:
 Shear waves
 Compression waves
 Lamb waves
 Rayleigh waves
 Reflection and refraction
 There are 4 types of probe Techniques:
 Lateral
 Transverse
 Orbital
 Rotational.
 UT tools contain:
 Probe: searching unit ( transducer
 Piezoelectricity: it’s producing waves by
converting a electrical energy to mechanical
energy. Therefore echo is produced.
 Type of probes:
 Normal probe
 Angle probe
 Single crystal probe
 Dual crystal probe
 Equipment Calibration
3/20/2016

 Hardness: its property of
materials that enable to resist
plastic deformation by
penetration and its resist
bending, cutting, scratching.
 Definition: fundamental units of
mass, length, and time. Usually
used for CS, SS, and DSS
materials. AS per ASTM E734.
 Type of Hardness:
 Rockwell “HR
 Brinell hardness “HBW”:
 Vickers hardness “HV
 Knoop Hardness “HK
 Ferrite hardness test
 PMI: positive materials
identification, its an
instrument analysis the
elements in the materials.
 Example CS, and SS material. In
DSS the chromium percentage is
22%, and 25% , and 27%. And
the Nickel percentage is 0.5%-
5%. PMI identify the percentage
of the element in the material.
 DSS = 2205
 SDSS =2505
 SDSS= 2705
 UNS Unified Numbering System:
 UNS of DSS = 31803
3/20/2016

M6/ Mechanical/Painting & Insulation
 Define painting: paint is a mixture of
binder pigment and solvent.
 Binder: its ability to bind with surface at
the condition of the surface preparation &
shall be free of dust.
 Pigment: Its element adds color to the
paint
 Type of pigment:
 Synthetic or artificial: its extracted from
petrochemicals, coaltar for black,
phosphar for yellow, zinc phosphate for
red.
 Natural color: its organic color like
limestone for white, fruit skin extracts
colors.
 Solvent: its an element add to the paint
to keep it in liquid stage of temperature
set by manufacturer
 Category of paint:
 Organic paint Epoxy polymers: ex.
Phinollic, polyester, polyurethane,
polyureas.
 Inorganic paint: are zinc silicates, zinc
phosphate, and aluminum base paint.
 Uses of paint:
 For protection.
 For reflection
 For marine service protection
 Leak protection.
 Weather proofing
 Type of paint application technique:
 Brushing
 Rolling
 Spraying
 Powder type
3/20/2016

 Solvent: solvent are made from petrochemicals
process such as, mineral spiret, lower alcohol,
oxidizing chemicals, which evaporate above
normal temperature.
 Polyurethane: its also known as PU paint/
coating.
 Epoxy is a term used to denote both the basic
components of epoxy resins, as well as colloquial
name for epoxide. Epoxy resins also known as
polyepoxides are a class of reactive pre polymers
& polymers which contain epoxide. Epoxy resins
may be reacted either with themselves through
polymerization, or with a wide range of co-
reactants including polyfunctional amines acids,
phenols, alcohols & thiols. These co-reactants are
often referred to as hardeners or curatives, and
the cross-linking reaction is commonly referred to
as curing. Reaction of poly epoxides themselves
or with polyfunctional hardeners forms a
thermosetting polymer, often with high mechanical
properties, temperature and chemical resistance.
Epoxy has a wide range of applications, including
metal coatings, used in electronics/electrical
components, fiber-reinforced plastic materials &
structural adhesives it is non glossy & UV
protective.
 Zinc phosphate: It is an inorganic chemical
compound used as a corrosion resistant coating on
metal surfaces either as part of an electroplating
process or applied as a primer pigment
 Metallic paint:
 Aluminum based paint: its contain metallic
pigment aluminum, its extracted from aluminum,
cure at high temperature.
 Mixing ratio:
 Single pack paint: (metallic paints) which are
ready to use, and it doesn’t have hardener, and
its cure at high temperature.
 Two pack system: it’s a paint component which
has a base and hardener, where MSDS (material
safety data sheet) specified the mixing ratio
application during pot life.
 Storage of paint container:
 Data sheet requirement
 Definition of pot life:
 Shelf life:
 Specific gravity (SP)
 Volume solid
 Surface or component in painting terminology
 Volatile organic component (V.O.C):
 Flash point
3/20/2016

 Construction of painting yard:
 Rust Grades
 Grade A Steel with mill scale layer
intact and very minor, or no rusting
 Grade B Steel with spreading
surface rust and the mill scale
commenced flaking
 Grade C Rusty steel with mill scale
layer flaked and loose or lost but only
minor Occurrence of pitting
 Grade D Very rusty steel with mill
scale layer all rusted and extensive
occurrence Of pitting.
 Preparation grades Scraping and
wire-brushing
 St 2 Thorough scraping
 St 3 Very thorough scraping
 Preparation grades. Blast cleaning
 Sa 1 Light blast cleaning
 Sa 2 Thorough blast cleaning.
 Sa 2½ Very thorough blast cleaning.
 Sa 3 Blast cleaning to pure metal
 Abrasive type of materials:
 Garnet
 Copper slag
 Metal shot
 Crushed glass
3/20/2016

 Garnet: it’s a natural element
extracted from the stone, it has
calcium carbonate crystal
structure diamond shape,
 Copper slag: its granulated slag
made from metal smelting process. It
iron ore exposed to high temperature in
Furness, impurities are removed or
separated, and all slag component
removed oxides are added
 Metal shot:: companion of metal
steel balls, it size will be less than
1mm, it has spherical shape, it can
be reused up to 20 times, it used in
closed chambers, it doesn’t have any
dust.
 Crushed glass: its
mixture of crushed
glass, basically its
used in glass
chamber, its has
low surface profile
(roughness).

3/20/2016
Industrial Application Non industrial application

3/20/2016
 Storing place for paints
 Painters’ qualification
 Spray painting types & technique:
 Pressure type – LVLP .
 HVLP type .
 Brush painter.
 Profile preparation
 Quantitative test:
 Bresle patch test
 Qualitative test: its done by several tests like: bend test, knife cross test,
impact test, peel test, adhesion test, push test.
 Bend test
 Knife cross cut
 Push test
 Peel test

 Insulation: In securing inner
component by placing or adding
a layer of mineral fiber or glass
wool or layer of ceramic, or foam
type material which prevent or
protect loss of inner temperature
and shielding from external
weather condition.
 Major aim of insulation is
personnel protection, hot loss,
weather condition. mostly its
used in the process plants for
maintaining temperature in
process vessels & equipments
and related piping, for example:
Hot & Cold Insulation.
 Type of Insulation:
 Cold insulation
 Hot insulation
 Personnel protection
 Zinc protection
 The common materials
used to protection are:
 Cellular
 Mineral wool
 Ceramic wool
 Rigid polyurethane foam
 polyisocyanurate foam “PIR”
 Application of insulation
3/20/2016

M11/ Commissioning / SNGP, SNDC&
SNCP Process overview
3/20/2016
 SNGP process block diagram: its shows the whole process
of the gas in SNGP, each process explained in details.
 RMS: remote manifold station, which they collect far wells
and in one pipeline then send it to SNOS.
 Dehydration: it’s a process which its remove all the
condensate from the gas and produce dry gas.
 TEG regeneration: tri ethylene glycol, glycol system the main
purpose of it, is to all contamination of water (moisture) from
the gas during dehydration process.
 SNDC: Saih Nihayda Depletion Compressors, the main aim
of SNDC was to increase the Gas pressure in SNGP after it
was reduced from wells. It consist of three Reciprocating
Compressors inside the SNGP and its on the begin of the
process.

M11/ Commissioning / SNGP, SNDC&
SNCP Process overview
 SNCP: Saih Nihayda Condensate Plant.
 Instrument Air System
 Fuel Gas
 Flare system: to have safe area for
releasing excess gas and also for blow
down of the plant. It usually burns the
excess air. The main factor of it to
collected the hydrocarbon relieve form
the plant, it has two type:
 HP: high pressure.
 AP: Atmospheric Pressure
 Knockout Drum
 Open Hazardous drain
 Closed drain
 Slug Catcher V-6901
 Scopentoeter Device
 Mismat
 Plate Pack coaleser
 HP inlet flash vessel V-6902
 LP inlet flash vessel V-6903
 Dry condensate flash vessel V-6904
 Water coalecer A-6940
 Condensate stabilizer C-6901
 Stabilizer Side Heater E-6901
 Stabilizer Re-boiler E-6902:
 Bottom heat exchanger E-6904:
 Top Heat exchanger E-6903
 Flash Gas compressor
 SNCP (HTF) Heat Transfer Fuel:
 After cooling
 Exporting of stabilized condensate
3/20/2016

presentation

Recommandé

Recommandé

Contenu connexe

Tendances

Tendances (20)

En vedette

En vedette (18)

Similaire à presentation

Similaire à presentation (20)

presentation